CN103562622A - Color conversion cavity for LED-based lighting modules - Google Patents

Abstract

The lighting module (100) comprises a plurality of Light Emitting Diodes (LEDs) (102a, 102b, 102 c). There are a plurality of color conversion cavities (160a, 160b, 160c), each having sidewalls coated with a wavelength converting material (162, 16, 165). One or more LEDs are located within each color conversion cavity. A transmissive layer (134) may be disposed over the color conversion cavity and may include additional wavelength converting material. The wavelength converting material may be selected to produce output light having a target color point. Additionally, there may be a second light mixing cavity (170) above the plurality of color conversion cavities.

Description

Color conversion cavity for LED-based lighting modules

Cross References to Related Applications

This application claims priority to U.S. Patent Application No. 13/431,796, filed March 27, 2012, which in turn claims priority under 35USC119 to U.S. Provisional Patent Application No. 61/470,389, filed March 31, 2011 rights, the entire contents of these two patent applications are hereby incorporated by reference.

technical field

The described embodiments relate to lighting modules comprising light emitting diodes (LEDs).

Background technique

The use of light emitting diodes in general lighting remains limited due to limitations in the level of light output, or flux, produced by such lighting devices. Lighting devices using LEDs also generally suffer from poor color quality characterized by color point instability. The color point instability varies over time and between sections. Poor color quality is also characterized by poor color rendering due to the spectrum produced by LED light sources in frequency bands with no or very little power. Furthermore, lighting devices using LEDs often have spatial and/or angular variations in the color. Also, due to the need, among other things, for color control electronics and/or sensors to maintain the color point of the light source or to use only a fraction of the LEDs produced to meet the color and/or flux requirements of the application , Lighting equipment using LEDs is expensive.

Therefore, there is a need for improvements to lighting devices utilizing light emitting diodes as light sources.

Contents of the invention

The lighting module includes a plurality of light emitting diodes (LEDs). There are a plurality of color converting cavities each having sidewalls coated with a wavelength converting material. One or more LEDs are located within each color converting cavity. A transmissive layer may be deposited over the color converting cavity and may include additional wavelength converting material. The wavelength converting material can be selected to produce output light with a target color point. Additionally, there may be a second light mixing cavity above the plurality of color conversion cavities.

Additional details are described in the detailed description below, along with embodiments and techniques. This summary does not limit the invention. The invention is defined by the following claims.

Description of drawings

Figures 1, 2, and 3 illustrate three exemplary light sources comprising lighting fixtures, reflector reflectors, and fixtures.

FIG. 4 shows an exploded view illustrating the components of the LED-based lighting device as described in FIG. 1 .

5A and 5B illustrate perspective and cross-sectional views of an LED-based lighting device as described in FIG. 1 .

Figure 6 illustrates a cross-sectional view of an LED-based lighting module including reflective and transmissive color conversion elements coated with a layer of phosphor.

7 illustrates a cross-sectional view of a portion of an LED lighting module with a transmissive color converting element having a color converting layer with phosphor particles.

8 illustrates a cross-sectional view of a portion of an LED lighting module having a reflective color converting element with fluorescent particles.

9-13 depict cross-sectional side views of various embodiments of LED-based lighting modules 100 including multiple color converting cavities.

14A-14E depict cross-sectional top views of various embodiments of LED-based lighting modules that include multiple color converting cavities.

15, 16 and 17 depict cross-sectional side views of various embodiments of LED-based lighting modules having a grid structure mounted to a transmissive layer.

18 depicts a cross-sectional top view of an LED-based lighting module having a grid structure mounted to a transmissive layer.

19 depicts a cross-sectional side view of another embodiment of an LED-based lighting module having a grid structure mounted to a transmissive layer.

20 illustrates a cross-sectional view of an LED-based lighting module including a color conversion cavity configured to disperse and color convert light emitted from an LED over a wide area.

21 illustrates a cross-sectional view of an LED-based lighting module with a color converting cavity.

22, 23 and 24 illustrate cross-sectional side views of an LED-based lighting module including a translucent non-planar non-planar shaped window disposed over and spaced from the LEDs.

Detailed ways

Reference will now be made in detail to background examples and some embodiments of the invention that are illustrated in the accompanying drawings.

1 , 2 and 3 illustrate three exemplary light sources, all labeled 150 . The light source illustrated in FIG. 1 includes a lighting module 100 having a rectangular form factor. The light source illustrated in FIG. 2 includes a lighting module 100 having a circular form factor. The light source illustrated in Fig. 3 comprises a lighting module 100 integrated in a retrofit light installation. These examples are for illustration purposes. Examples of generally polygonal and elliptical lighting modules are also conceivable. The light source 150 includes a lighting module 100 , a reflector 125 and a fixing device 120 . As shown, fixture 120 includes heat sink capability, and may therefore sometimes be referred to as heat sink 120 . However, the fixture 120 may include other structural and decorative elements (not shown). The reflector 125 is installed to the lighting module 100 to collimate or deflect light emitted from the lighting module 100 . The reflector 125 may be made of thermally conductive material, such as a material including aluminum or copper, and may be thermally coupled to the lighting module 100 . Heat flows through the lighting module 100 and the heat-conducting reflector 125 by conduction. Heat also flows through thermal convection above the reflector 125 . Reflector 125 may be a compound parabolic concentrator, wherein the concentrator is constructed of or coated with a highly reflective material. Optical elements, such as diffusers or reflectors 125, may be removably coupled to lighting module 100, such as with wires, clips, twist-and-lock mechanisms, or other suitable structures. As shown in FIG. 3, the reflector 125 may include sidewalls 126 and windows 127, optionally coated with, for example, a wavelength converting material, diffusing material, or any other desired material.

As shown in FIGS. 1 , 2 and 3 , the lighting module 100 is mounted to a heat sink 120 . The heat sink 120 may be made of a thermally conductive material, such as a material including aluminum or copper, and may be thermally coupled to the lighting module 100 . Heat flows through the lighting module 100 and the heat conducting heat sink 120 by conduction. Heat also flows through thermal convection over the heat sink 120 . The lighting module 100 may be screwed to the heat sink 120 to clamp the lighting module 100 to the heat sink 120 . In order to facilitate the disassembly and replacement of the lighting module 100, the lighting module 100 may be detachably coupled to the heat sink 120, for example, by using a clamping mechanism, a twist locking mechanism, or other suitable structures. The lighting module 100 includes at least one thermally conductive surface that is thermally coupled to the heat sink 120 , eg, directly or using thermally conductive paste, thermally conductive tape, thermally conductive spacer, or thermal epoxy. For adequate cooling of the LEDs, a thermal contact area of at least 50 mm2 but preferably 100 mm2 should be used per watt of electrical power flowing into the LEDs on the board. For example, where 20 LEDs are used, a heat sink contact area of 1000 to 2000 square millimeters should be used. Using a larger heat sink 120 may allow the LED 102 to be driven at higher power and also allow for different heat sink designs. For example, some designs may exhibit cooling performance that is less dependent on the orientation of the heat sink. Furthermore, fans or other solutions for forced cooling can be used to remove heat from the device. The bottom heat sink may include a hole so that an electrical connection to the lighting module 100 can be made.

Fig. 4 shows an exploded view illustrating by way of example the components of the LED-based lighting device as described in Fig. 1 . It should be understood that an LED-based lighting module, as defined herein, is not an LED, but an LED light source or fixture or an integral part of an LED light source or fixture. For example, the LED-based lighting module may be an LED-based replacement light bulb as shown in FIG. 3 . The LED-based lighting module 100 includes one or more LED dies or packaged LEDs and a mounting board to which the LED dies or packaged LEDs are attached. In one embodiment, the LED 102 is a packaged LED, such as a Luxeon Rebel manufactured by Philips Lumileds Lighting. Other types of packaged LEDs can also be used, such as those produced by OSRAM (Oslonpackage), Luminus Devices (USA), Cree (USA), Nichia (Japan) or those manufactured by the company Tridonic (Austria). As defined herein, a packaged LED is an assembly of one or more LED dies that contain electrical connections, such as wire bond connections or stud bumps, and may include optical elements and thermal, mechanical, and electrical interface. The LED chips typically have dimensions of about 1 mm x 1 mm x 0.5 mm, although these dimensions may vary. In some embodiments, the LED 102 may include multiple chips. The plurality of chips may emit light of similar or different colors (eg, red, green, and blue). Mounting plate 104 is attached to mounting base 101 and is held in place by mounting plate retaining ring 103 . Meanwhile, the mounting plate 104 populated by LEDs 102 and the mounting plate positioning ring 103 include the light source subassembly 115 . Light source subassembly 115 may be used to convert electrical energy to light using LED 102 . Light emitted from light source subassembly 115 is directed to light conversion subassembly 116 for color mixing and color conversion. The light conversion subassembly 116 includes a cavity 105 and an output port, denoted as but not limited to an output window 108 . Light conversion subassembly 116 optionally includes either or both of bottom reflector insert 106 and sidewall insert 107 . If used as the output port, the output window 108 is fixed to the cavity 105 with an adhesive. To facilitate heat dissipation from the output window to cavity 105, a thermally conductive adhesive is desirable. The adhesive should reliably withstand the temperatures occurring at the interface of the output window 108 and cavity 105 . Furthermore, it is preferred that the adhesive reflect or transmit as much incident light as possible, rather than absorbing light emitted from the output window 108 . In one example, the heat resistance, thermal conductivity, and A combination of optical and optical properties provides suitable performance. However, other thermally conductive adhesives are also contemplated.

When optionally placed within cavity 105, the inner sidewall or sidewall insert 107 of cavity 105 is reflective such that light from LED 102, as well as converted light of any wavelength, is transmitted through the output port (e.g., output Window 108 ) is previously reflected in the cavity 160 , and the output port is mounted above the light source subassembly 115 . A bottom reflector insert 106 may optionally be placed above the mounting plate 104 . Bottom reflector insert 106 includes holes such that the light emitting portion of each LED 102 is not blocked by bottom reflector insert 106 . Sidewall insert 107 may optionally be placed within cavity 105 such that when cavity 105 is mounted above light source subassembly 115, the inner surface of sidewall insert 107 directs light from the LED 102 toward the output window. . Although as shown, the inner side walls of the cavity 105 are rectangular as viewed from the top of the lighting module 100, other shapes (eg, trilobal or polygonal) are contemplated. In addition, the inner side walls of the cavity 105 may taper or curve outward from the mounting plate 104 to the output window 108 rather than being perpendicular to the output window 108 as shown.

的材料。可以通过对铝进行抛光或者通过用一种或者多种反射性涂层覆盖插入件106和107的内表面实现高的反射性。插入件106和107可以替代地由高反射薄材料制成，诸如由3M公司(美国)出售的Vikuiti^TMESR、由东丽(Toray)公司(日本)制造的Lumirror^TME60L或者微晶聚对苯二甲酸乙二醇酯(MCPET)，诸如由古河电气(Furukawa Electric)有限公司(日本)制造的。在其他示例中，插入件106和107可以由聚四氟乙烯(PTFE)材料制成。在一些示例中，插入件106和107可以由1至2毫米厚的PTFE材料制成，如由W.L.Gore公司(美国)和Berghof公司(德国)出售的。在另外一些实施例中，插入件106和107可以由PTFE材料构成，背后是薄的反射层，诸如金属层或者非金属层，诸如ESR、E60L或者MCPET。同样，可以将高漫反射涂层施加至侧壁插入件107、底部反射体插入件106、输出窗口108、腔体105和安装板104的任一个。这种涂层可以包括二氧化钛(TiO2)、氧化锌(ZnO)和硫酸钡(BaSO4)粒子，或者这些材料的组合。The bottom reflector insert 106 and the sidewall inserts 107 may be highly reflective such that light reflected downward in the cavity 160 is generally emitted back to the output section, such as the output window 108 . Additionally, inserts 106 and 107 may have high thermal conductivity such that it acts as an additional heat sink. As an example, the inserts 106 and 107 may be made of a highly thermally conductive material, such as an aluminum-based material that can be processed into a highly reflective and durable material. As an example, the so-called

s material. High reflectivity can be achieved by polishing the aluminum or by covering the inner surfaces of inserts 106 and 107 with one or more reflective coatings. Inserts 106 and 107 may alternatively be made of highly reflective thin material such as Vikuiti ^™ ESR sold by 3M Company (USA), Lumirror ^™ E60L manufactured by Toray Company (Japan), or microcrystalline polyparaphenylene Ethylene glycol dicarboxylate (MCPET), such as that manufactured by Furukawa Electric Co., Ltd. (Japan). In other examples, inserts 106 and 107 may be made of polytetrafluoroethylene (PTFE) material. In some examples, inserts 106 and 107 may be made of 1 to 2 mm thick PTFE material, as sold by WL Gore (USA) and Berghof (Germany). In other embodiments, inserts 106 and 107 may be constructed of PTFE material behind a thin reflective layer such as a metal layer or a non-metal layer such as ESR, E60L or MCPET. Likewise, a highly diffuse reflective coating may be applied to any of sidewall insert 107 , bottom reflector insert 106 , output window 108 , cavity 105 , and mounting plate 104 . Such coatings may include titanium dioxide (TiO2), zinc oxide (ZnO), and barium sulfate (BaSO4) particles, or combinations of these materials.

5A and 5B illustrate perspective and cross-sectional views of the LED-based lighting module 100 as described in FIG. 1 . In this embodiment, the sidewall insert 107, output window 108, and bottom reflector insert 106 disposed on the mounting plate 104 define a light mixing cavity 160 in the LED-based lighting module 100 (eg, Figure 5A). A portion of the light from the LEDs 102 is reflected within the light mixing cavity 160 before exiting through the output window 108 . Reflecting within the cavity 160 before exiting the output window 108 has the effect of mixing the light and providing a more even distribution of the light emitted from the LED-based lighting module 100 . Furthermore, due to the reflection of the light within the cavity 160 before exiting the output window 108 , a portion of the light undergoes color conversion by interacting with the wavelength converting material included in the cavity 160 .

Although the LED-based lighting module 100 includes a single color conversion cavity 160 as shown in FIGS. 1-5B , other embodiments may be described herein. In an aspect, the output window 108 may be a three-dimensionally shaped housing structure to facilitate light extraction, color conversion, and shaping of the output beam profile. In another aspect, a grid structure forming a plurality of pocket structures may be connected to the window of the LED-based lighting module 100 . By coating different pocket structures with different wavelength conversion materials, the color point of light emitted from the lighting module 100 can be tuned and output beam uniformity can be improved. In another aspect, LED-based lighting module 100 may include multiple color conversion cavities 160, each cavity surrounding a different LED or group of LEDs. By varying the color conversion properties of different color conversion cavities 160, the color point of the light emitted from the lighting module 100 can be tuned and the output beam uniformity can be improved. Furthermore, a second mixing cavity may be arranged to collect the light emitted from each color conversion cavity and further mix the light before exiting the lighting module 100 . In another aspect, the color conversion cavity may be configured to disperse and color convert light emitted from the LED 102 over a wider area by transmitting light laterally and away from the LED by a series of reflections within the color conversion cavity. In some examples, light emitted from the LED can be color converted by a wavelength converting material embedded within the color converting cavity. In some examples, light emitted from the LED can be color converted by a wavelength converting material located at the output of the color converting cavity.

LEDs 102 may emit different or the same color by direct emission or by phosphor conversion where a phosphor layer is applied to the LED as part of the LED package. The lighting device 100 may use any combination of colored LEDs 102, such as red, green, blue, amber or cyan, or the LEDs 102 may all produce the same color of light. Some or all of LEDs 102 may produce white light. Furthermore, the LEDs 102 can emit polarized or non-polarized light, and the LED-based lighting device 100 can utilize any combination of polarized or non-polarized LEDs. In some embodiments, LED 102 emits blue or ultraviolet light due to the LED's luminous efficiency in these wavelength ranges. When the LEDs 102 are used in combination with the wavelength converting material included in the color converting cavity 160, the light emitted from the lighting device 100 has a desired color. The photon conversion properties of the wavelength conversion material combined with light mixing within the cavity 160 result in a color converted light output. By tuning the chemical and/or physical (such as thickness and concentration) properties of the wavelength converting material and the geometric properties of the coating on the inner surface of the cavity 160, specific color properties, such as a color point, of the light output by the output window 108 can be specified. , color temperature and color rendering index (CRI).

For the purposes of this patent document, a wavelength conversion material is any single chemical compound or mixture of different chemical compounds that performs a color conversion function such as absorbing some light at one peak wavelength and, in response, emitting at another peak wavelength some light here.

Portions of cavity 160, such as the bottom reflector insert 106, sidewall inserts 107, cavity body 105, output window 108, and other components (not shown) placed within the cavity may be coated or include wavelength conversion material. Figure 5B illustrates the portion of the sidewall insert 107 coated with wavelength converting material. Furthermore, different components of cavity 160 may be coated with the same or different wavelength converting materials.

As an example, phosphors may be selected from the group represented by the following chemical formulas: Y ₃ Al ₅ O ₁₂ :Ce, (also known as YAG:Ce, or simply YAG), (Y,Gd) ₃ Al ₅ O ₁₂ :Ce, CaS: Eu, SrS: Eu, SrGa ₂ S ₄ : Eu, Ca ₃ (Sc, Mg) ₂ Si ₃ O ₁₂ : Ce, Ca ₃ Sc ₂ Si ₃ O ₁₂ : Ce, Ca ₃ Sc ₂ O ₄ : Ce, Ba ₃ Si ₆ O ₁₂ N ₂ : Eu, (Sr, Ca)AlSiN ₃ : Eu, CaAlSiN ₃ : Eu, CaAlSi(ON) ₃ : Eu, Ba ₂ SiO ₄ : Eu, Sr ₂ SiO ₄ : Eu, Ca ₂ SiO ₄ : Eu, CaSc ₂ O ₄ : Ce, CaSi ₂ O ₂ N ₂ : Eu, SrSi ₂ O ₂ N ₂ : Eu, BaSi ₂ O ₂ N ₂ : Eu, Ca ₅₍ PO ₄ ) ₃ Cl: Eu, Ba ₅₍ PO ₄ ) ₃ Cl: Eu, Cs ₂ CaP ₂ O ₇ , Cs ₂ SrP ₂ O ₇ , Lu ₃ Al ₅ O ₁₂ : Ce, Ca ₈ Mg(SiO ₄ ) ₄ Cl ₂ : Eu, Sr ₈ Mg (SiO ₄ ) ₄ Cl ₂ : Eu, La ₃ Si ₆ N ₁₁ : Ce, Y ₃ Ga ₅ O ₁₂ : Ce, Gd ₃ Ga ₅ O ₁₂ : Ce, Tb ₃ Al ₅ O ₁₂ : Ce, Tb ₃ Ga ₅ O ₁₂ : Ce, and Lu ₃ Ga ₅ O ₁₂ : Ce.

In one example, adjustment of the color point of the lighting device can be achieved by replacing the sidewall insert 107 and/or the output window 108, similarly by coating or impregnating one or more wavelength conversion materials. In one example, a red emitting phosphor (such as europium activated alkaline earth metal silicon nitride, eg (Sr,Ca)AlSiN ₃ :Eu) covers the sidewall insert 107 and the bottom reflector insert 106 at the bottom of the cavity 160 part of the output window 108, and the YAG phosphor covers a part of the output window 108. In another embodiment, a red emitting phosphor such as alkaline earth silicon oxynitride covers a portion of the sidewall insert 107 and the bottom reflector insert 106 at the bottom of the cavity 160, and a red emitting alkaline earth metal oxynitride A mixture of silicon carbide and yellow-emitting YAG phosphor covers a portion of the output window 108 .

In some embodiments, the phosphor is mixed with a binder and optionally a surfactant and a plasticizer in a suitable solution medium. The resulting mixture is deposited by any of spray coating, screen printing, doctor blade coating, or other suitable means. By selecting the shape and height of the side walls defining the cavity, and selecting which parts in the cavity will be covered or not covered by phosphor, and by the layer thickness and concentration of the phosphor layer on the surface of the light mixing cavity 160 For optimization, the color point of the light emitted from the module can be tuned as desired.

In one example, a single type of wavelength conversion material can be patterned on the sidewall, such as sidewall insert 107 as shown in FIG. 5B . As an example, red phosphor may be patterned on different areas of the sidewall insert 107 and yellow phosphor may cover the output window 108 . The phosphor coverage area and/or concentration can be varied to produce different color temperatures. It should be understood that if the light produced by the LEDs 102 is varied, then the red coverage area and/or the red and yellow phosphor concentrations will need to be varied to produce the desired color temperature. The color performance of the LEDs 102, the red phosphor on the sidewall insert 107 and the yellow phosphor on the output window 108 can be measured prior to assembly and selected based on performance such that the assembly produces the desired color temperature .

In many applications, it is desirable to produce a white light output with a correlated color temperature (CCT) of less than 3100 degrees Kelvin. For example, in many applications white light with a CCT of 2700 degrees Kelvin is desired. Some red emission is generally required to convert light produced from LEDs emitting in the blue or ultraviolet portion of the spectrum to a white light output with a CCT of less than 3100 degrees Kelvin. Efforts are underway to combine yellow phosphors with red-emitting phosphors, such as CaS:Eu, SrS:Eu, SrGa ₂ S ₄ :Eu, Ba ₃ Si ₆ O ₁₂ N ₂ :Eu, (Sr,Ca)AlSiN ₃ :Eu, CaAlSiN ₃ : Eu, CaAlSi(ON) ₃ : Eu, Ba ₂ SiO ₄ : Eu, Sr ₂ SiO ₄ : Eu, Ca ₂ SiO ₄ : Eu, CaSi ₂ O ₂ N ₂ : Eu, SrSi ₂ O ₂ N ₂ : Eu , BaSi ₂ O ₂ N ₂ : Eu, Sr ₈ Mg(SiO ₄ ) ₄ Cl ₂ : Eu, Li ₂ NbF ₇ : Mn ⁴⁺ , Li ₃ ScF ₆ : Mn ⁴⁺ , La ₂ O ₂ S: Eu ³⁺ and MgO.MgF ₂ .GeO ₂ :Mn ⁴⁺ , mixed to achieve the desired CCT. However, since the CCT of the output light is sensitive to the red phosphor component in the mixture, the color consistency of the output light is generally poor. Poor color distribution is more pronounced in the case of mixed phosphors, especially in lighting applications. By coating the output window 108 with a phosphor or phosphor mixture that does not include any red emitting phosphor, color consistency problems can be avoided. To produce a white light output with a CCT of less than 3100 degrees Kelvin, a red emitting phosphor or phosphor mixture is deposited on either the sidewalls and the bottom reflector of the LED-based lighting module 100 . The specified red emitting phosphor or phosphor blend (eg, peak emission wavelength from 600 nm to 700 nm) and the concentration of the red emitting phosphor or phosphor blend are selected to produce a white light output with a CCT of less than 3100 degrees Kelvin. In this way, an LED-based lighting module can produce white light with a CCT of less than 3100K with an output window that does not include a red-emitting phosphor component.

For LED-based lighting modules, it is desirable to convert a portion of the light emitted by the LEDs to longer wavelength light in at least one light mixing cavity 160 while minimizing photon losses. Thin layers of densely packed phosphors are suitable for efficient color conversion of a significant fraction of incident light while minimizing losses associated with reabsorption, total internal reflection (TLR) and Fresnel effects of adjacent phosphor particles minimized.

FIG. 6 illustrates a cross-sectional view of color conversion cavity 160 with emphasis on the interaction of light emitted by LED 102 with the components of cavity 160 . As shown, the color conversion cavity 160 includes a reflective color conversion element 130 and a transmissive color conversion element 133 . The transmissive color conversion element 133 comprises a color conversion layer 135 secured to an optically transmissive layer 134 . The reflective color conversion element 130 includes a color conversion layer 132 fixed to a reflective layer 131 .

The transmissive color conversion element 133 provides efficient color conversion in transmissive mode. The color conversion layer 135 includes a sparse phosphor thin layer. In lighting devices pumped by UV or sub-UV radiation, the transmission of unconverted light is undesirable because of the health risks to humans from exposure to radiation at these wavelengths. However, for LED-based lighting modules pumped by LEDs emitting wavelengths above the ultraviolet, it is expected that a significant proportion of unconverted light (eg, blue light emitted from LED 102 ) passes through light mixing cavity 160 without color conversion. This promotes high efficiency because losses inherent in the color conversion process are avoided. Thin layers of sparsely packed phosphors are suitable for color conversion of a fraction of the incident light. For example, it is desirable to allow at least 10% of incident light to be transmitted through the layer without conversion.

The reflective color conversion element 130 provides efficient color conversion in reflective mode. A color conversion layer 132 having a desired thickness at high density is deposited on the reflective layer 131 . In some embodiments, it is desirable to have a thickness greater than 90% of the average diameter of the fluorescent particles. In these embodiments, the average fluorescent particle diameter is between 6 and 8 microns.

FIG. 7 illustrates a cross-sectional view of the LED lighting module 100 focusing on the interaction of photons emitted by the LED 102 with the transmitted color conversion element 133 . Transmissive layer 134 may be composed of an optically transparent medium (eg, glass, sapphire, polycarbonate, plastic). The transmissive layer 134 can also be made of a translucent material (such as a thin layer of PTFE or an etched optically transparent medium). Transmissive color conversion element 133 may include additional layers (not shown) to enhance optical system performance. In one example, the transmissive color converting element 133 may include an optical film such as a dichroic filter, a low index coating, an additional layer such as a layer of scattering particles, or an additional color converting layer including fluorescent particles. In some embodiments, the translucent color conversion layer 135 includes fluorescent particles 141 embedded in a polymeric binder 142 . Phosphor particles 141 are provided to enable a portion of the light to be transmitted through the transmissive color conversion element 133 without color conversion.

In one embodiment, the translucent color conversion layer 135 deposited on the optically transmissive layer 134 has a thickness T ₁₃₅ that is three times the average diameter of the phosphor particles with a packing density of about 80%. In this example, the average fluorescent particle diameter is 10 microns.

As shown in FIG. 7, blue photons 139 emitted by LED 102 pass through transmission color conversion element 133 without color conversion and contribute to combining light 140 as blue photons. However, blue photons 138 emitted by LED 102 are absorbed by phosphor particles embedded in color conversion layer 135 . In response to the excitation provided by blue photons 138, the phosphor particles emit longer wavelength light in an isotropic emission pattern. In the illustrated example, the fluorescent particles emit yellow light. As shown in FIG. 7, a portion of the emitted yellow light passes through the transmission color conversion element 133 and contributes to combined light 140 as yellow photons. Another part of the emitted yellow light is absorbed by adjacent fluorescent particles and is re-emitted or lost. Another part of the emitted yellow light is scattered back to the light mixing cavity 160 where it is reflected back to the transmissive color converting element 133 or absorbed and lost within the light mixing cavity 160 .

FIG. 8 illustrates a cross-sectional view of color conversion cavity 160 focusing on the interaction of photons emitted by LED 102 with reflective color conversion element 130 . In some embodiments, the color conversion layer 132 has a thickness T ₁₃₂ that is less than five times the average diameter of the fluorescent particles 141 . The average diameter of the fluorescent particles 141 can be 1 micron to 25 microns. In some embodiments, the average diameter of the fluorescent particles 141 is 5-10 microns. The fluorescent particles 141 are set to a packing density greater than 80% to increase the probability of incident photons interacting with the fluorescent particles to generate converted light. For example, blue photons 137 emitted by LED 102 are incident on reflective color converting element 130 and are absorbed by fluorescent particles of color converting layer 132 . In response to the excitation provided by blue photons 137, the phosphor particles emit longer wavelength light in an isotropic emission pattern. In the illustrated example, the fluorescent particles emit red light. As shown in FIG. 8 , a portion of the emitted red light enters the light mixing cavity 160 . Another portion of the red-emitting light is absorbed by adjacent phosphor particles and either re-emitted or lost. Another part of the emitted red light is reflected off the reflective layer 131 and transmitted through the color conversion layer 132 to the light mixing cavity 160 or absorbed by adjacent phosphor particles and re-emitted or lost.

9-13 depict cross-sectional side views of various embodiments of LED-based lighting modules 100 . FIG. 9 illustrates one aspect of an LED-based lighting module 100 including a plurality of color conversion cavities 160 . Each color conversion cavity (eg, 160a, 160b, and 160c) is configured to color convert the light emitted by each LED (eg, 102a, 102b, 102c), respectively, prior to combining the light from each color conversion cavity. By varying any chemical composition of one or more color conversion cavities, the geometric properties of the wavelength conversion coating in one or more color conversion cavities, the current supplied to any LED emitting into any color conversion cavities and one or more color conversion The shape of the cavity can control the color of light emitted from the LED-based lighting module 100 and can improve output beam uniformity.

As shown in FIG. 9, LED 102a only emits light directly into color conversion cavity 160a. Similarly, LED 102b only emits light directly into color conversion cavity 160b and LED 102c only emits light directly into color conversion cavity 160c. Each LED is isolated from each other by reflective side walls. For example, as shown, reflective sidewall 161 isolates LEDs 102a from 102b.

的材料。可以通过对铝进行抛光或者通过用一种或者多种反射性涂层覆盖反射侧壁161的内表面实现高的反射性。反射侧壁161可以替代地由高反射薄材料制成，诸如由3M公司(美国)出售的Vikuiti^TMESR、由Toray公司(日本)制造的Lumirror^TME60L或者微晶聚对苯二甲酸乙二醇酯(MCPET)，诸如由Furukawa Electric有限公司(日本)制造的。在其他示例中，反射侧壁161可以由PTFE材料制成。在一些示例中，反射侧壁161可以由1至2毫米厚的PTFE材料制成，如由W.L.Gore公司(美国)和Berghof公司(德国)出售的。在另外一些实施例中，反射侧壁161可以由PTFE材料构成，背后是薄的反射层，诸如金属层或者非金属层，诸如ESR、E60L或者MCPET。同样，可以将高漫反射涂层施加至反射侧壁161。这种涂层可以包括二氧化钛(TiO2)、氧化锌(ZnO)和硫酸钡(BaSO4)粒子，或者这些材料的组合。The reflective sidewalls 161 are highly reflective such that, for example, light emitted from the LED 102b is directed upwards into the color conversion cavity 160b , generally towards the output window 108 of the lighting module 100 . Furthermore, reflective sidewall 161 may have high thermal conductivity such that it acts as an additional heat sink. As an example, the reflective sidewalls 161 may be made of a highly thermally conductive material, such as an aluminum-based material that can be processed into a highly reflective and durable material. As an example, the so-called

s material. High reflectivity can be achieved by polishing the aluminum or by covering the inner surface of reflective sidewall 161 with one or more reflective coatings. The reflective side walls 161 may alternatively be made of highly reflective thin material such as Vikuiti ^™ ESR sold by 3M Company (USA), Lumirror ^™ E60L manufactured by Toray Company (Japan), or microcrystalline polyethylene terephthalate Ester (MCPET), such as that manufactured by Furukawa Electric Co., Ltd. (Japan). In other examples, reflective sidewall 161 may be made of PTFE material. In some examples, reflective sidewall 161 may be made of 1 to 2 mm thick PTFE material, as sold by WL Gore (USA) and Berghof (Germany). In other embodiments, the reflective sidewall 161 may be made of PTFE material behind a thin reflective layer, such as a metal layer or a non-metal layer, such as ESR, E60L or MCPET. Likewise, a highly diffuse reflective coating may be applied to the reflective sidewalls 161 . Such coatings may include titanium dioxide (TiO2), zinc oxide (ZnO), and barium sulfate (BaSO4) particles, or combinations of these materials.

In one aspect, LED-based lighting module 100 includes a first color converting cavity (eg, 160a) having an inner surface region coated with a first wavelength converting material 162, and a second color converting cavity (eg 160b ), the second color converting cavity has an inner surface region coated with a second wavelength converting material 164 . In some embodiments, the LED-based lighting module 100 includes a third color converting cavity (eg, 160c ) having an inner surface region coated with a third wavelength converting material 165 . In some other embodiments, the LED-based lighting module 100 may include additional color converting cavities comprising additional, different wavelength converting materials. In some embodiments, multiple color converting cavities include inner surface regions coated with the same wavelength converting material.

As shown in FIG. 9 , in one embodiment, the LED-based lighting module 100 further includes a transmissive layer 134 mounted above the color conversion cavity 160 . In some embodiments, transmissive layer 134 is coated with color converting layer 135 including wavelength converting material 163 . In one example, wavelength converting materials 162, 164, and 165 may include a red emitting phosphor material and wavelength converting material 163 includes a yellow emitting phosphor material. The transmissive layer 134 facilitates mixing of the light output by each color conversion cavity.

In some examples, each wavelength converting material included in color converting cavity 160 and color converting layer 135 is selected such that the color point of combined light 140 emitted from LED-based lighting module 100 matches a target color point.

In some embodiments, a second mixing chamber 170 is installed above the color conversion chamber 160 . The second mixing cavity 170 is a closed cavity that facilitates mixing of the light output by the color conversion cavity 160 so that the combined light 140 emitted from the LED-based lighting module 100 is uniform in color. As shown in FIG. 9 , the second mixing chamber 170 includes reflective sidewalls 171 installed along the periphery of the color conversion chamber 160 to capture the light output by said color conversion chamber 160 . The second mixing chamber 170 includes an output window 108 mounted above said reflective side wall 171 . Light emitted from the color conversion cavity 160 is reflected off the inner opposing surface of the second color conversion cavity and exits the output window 108 as combined light 140 .

As shown in FIG. 10 , in one embodiment, an LED-based lighting module 100 includes a color conversion cavity 160 and a second mixing cavity 170 . As shown, the output window 108 of the second mixing cavity 170 is coated by a color converting layer 135 comprising a wavelength converting cavity material 163 . In one example, wavelength converting materials 162, 164, and 165 may include a red emitting phosphor material and wavelength converting material 163 includes a yellow emitting phosphor material. A diffusion layer 143 mounted over the color conversion cavities 160 may optionally be included to facilitate mixing of the light output by each color conversion cavity. In some embodiments, diffusion layer 143 does not perform a color conversion function. Diffusion layer 143 may be composed of a translucent material (e.g., a thin layer of PTFE) or an optically transparent medium (e.g., glass, sapphire, polycarbonate, plastic) that has been processed (e.g., etched) or coated with a material (e.g., TiO ₂ ) coating to make it more optically diffuse.

As shown in Figures 9 and 10, the LED 102 is mounted on a plane and the reflective side wall 161 includes a flat surface oriented perpendicular to the plane on which the LED 102 is mounted. It has been found that flat, vertically oriented surfaces allow efficient color conversion of light while minimizing back reflections. However, other surface shapes and orientations are also contemplated. For example, FIG. 11 depicts a reflective sidewall 161 that includes a flat surface positioned at an oblique angle relative to the plane on which LED 102 is mounted. In some examples, this configuration facilitates the extraction of light from the color conversion cavity 160 .

Figure 12 depicts reflective sidewalls 161 in another embodiment. As shown, reflective sidewall 161 includes a tapered portion that includes a flat surface positioned at an oblique angle relative to the plane on which LED 102 is mounted. The tapered portion transitions to a flat surface positioned perpendicular to the plane on which the LED 102 is mounted. In other embodiments, the tapered portion includes a curved surface that transitions to a flat, vertical positioning surface. In some examples, these embodiments facilitate the extraction of light from the color conversion cavity 160 while efficiently color converting the light emitted by the LEDs 102 . Also, as shown in FIG. 11 , wavelength converting materials (eg, wavelength converting materials 162 , 164 and 165 ) are disposed on the flat, vertically oriented surfaces of reflective sidewall 161 .

As discussed above, by selecting each of the wavelength converting materials included in the color converting cavity 160 and by selecting the wavelength converting material included in the color converting layer 135, it is possible to tune the output from an LED based LED comprising multiple color converting cavities. The color of the light emitted by the lighting module 100 is adjusted to match the target color point. In other embodiments, the color of light emitted from the LED-based lighting module 100 can be tuned by selecting LEDs 102 with different peak emission wavelengths. For example, LED 102a may be selected to have a peak emission wavelength of 480 nanometers, while LED 102b may be selected to have a peak emission wavelength of 460 nanometers.

FIG. 13 depicts another embodiment for tuning the color of light emitted from an LED-based lighting module 100 comprising multiple color conversion cavities. By independently controlling the current supplied to the different LEDs 102, the flux emitted from each independently controlled color conversion cavity can be determined. In this way, the output flux of color conversion cavities having different color conversion characteristics can be tuned such that the color of light output from LED-based lighting module 100 matches a target color point. For example, power supply 180 provides current 184 on conductor 183 to LED 102a. Light emitted by LED 102a enters color conversion cavity 160a, undergoes color conversion and is emitted as color converted light 167. Similarly, power supply 181 provides current 186 on conductor 185 to LED 102b. Light emitted by LED 102b enters color conversion cavity 160b, undergoes color conversion and is emitted as color converted light 168 . By adjusting currents 184 and 186, the flux of color converted light 167 and the flux of color converted light 168 can be tuned such that the combination of color converted light 167 and 168 matches the target color point. Similarly, additional color conversion cavities can be independently controlled to tune the color point of the output light of LED-based lighting module 100 . As shown in FIG. 13 , power supply 182 provides current 188 on conductor 187 to LED 102c. Light emitted from LED 102c enters color conversion cavity 160c, undergoes color conversion and is emitted as color converted light 169 . In this manner, currents 184, 186, and 188 can be tuned so that the combination of color-converted light 167, 168, and 169 matches the target color point.

14A-14E depict cross-sectional top views of various embodiments of LED-based lighting modules 100 . Figure 14A depicts hexagonal color conversion cavities 160a-160g arranged in a close-packed configuration, where the side walls of each color conversion cavity are shared with the other. For example, each side wall of color conversion cavity 160g is shared with another color conversion cavity (160a-160f), respectively. Figure 14B depicts rectangular color conversion cavities 160a-160i arranged in a rectangular grid. In this configuration, the side walls of each color conversion cavity are shared with the other. For example, each side wall of color conversion chamber 160g is shared with color conversion chambers 160a-160f and 160h-160i, respectively. Figure 14C depicts rectangular color conversion cavities 160a-160f arranged in a hexagonal grid. In this configuration, the side walls of each color conversion cavity are shared with multiple color conversion cavities. For example, the side walls of color conversion cavity 160g are shared with color conversion cavities 160e and 160f. Figure 14D depicts circular color conversion cavities 160a-160i arranged in a hexagonal grid. Figure 14E depicts triangular color conversion cavities 160a-160f arranged in a close-packed hexagonal grid. In this configuration, the side walls of each color conversion cavity are shared with the other. The embodiment of Figures 14A-E is exemplary, but color conversion cavities of different shapes and layouts are also contemplated. For example, the color conversion cavity may be in the shape of an ellipse, a star, a general polygon, or the like. In addition, grid patterns can be selected that result in close-packed configurations. However, in other embodiments, grid patterns that are not tightly packed may be considered.

15 , 16 and 17 depict cross-sectional side views of various embodiments of an LED-based lighting module 100 having a grid structure 196 mounted to the transmissive layer 134 . In some embodiments, the transmissive layer 134 is the output window of the LED-based lighting module 100 . The grid structure 196 mounted to the transmissive layer 134 forms a plurality of pocket structures. Any number of pocket structures may be at least partially coated with some wavelength converting material. A grid structure mounted to or as part of a transmissive layer provides a means for color control using physically isolated pocket structures containing different wavelength converting materials. By varying the number of pockets with different wavelength converting materials, the color of the output light is controlled. In addition, the output beam uniformity is improved by evenly distributing the pocket structure of different wavelength conversion materials. Finally, efficiency can be improved by isolating different types of wavelength converting materials on a plane such that a significant portion of the light emitted from the LED is once absorbed by the wavelength converting material and re-emitted as output light. This structure minimizes the possibility of the color converted light being reabsorbed by the second wavelength converting material.

In the embodiment depicted in FIG. 15, some pockets are filled with red-emitting phosphor material 191, others are filled with green-emitting phosphor material 192, and still others are filled with yellow-emitting phosphor material 191. Phosphor material 190 is filled. In this manner, a portion of the light emitted from each LED is color converted into red, green, and yellow light as part of the combined light 140 emitted from the LED-based lighting module 100 . In some embodiments, mesh structure 196 is composed of PTFE material. Due to its effective diffuse reflective properties, PTFE promotes effective color conversion and allows some transmission of light from LED 102 through transmissive layer 134 without color conversion.

In some embodiments, such as those described in FIGS. 15 and 16 , the pocket structure is characterized by a depth D and a width W. FIG. By tuning the width and depth dimensions of the pocket structures and the composition of the wavelength converting material, the light emitted from the LED-based lighting module 100 can be matched to a target color point. Figure 17 illustrates an embodiment wherein the depth of the mesh structure extends from the transmissive layer 134 to a plane on which the LEDs 102 are mounted.

FIG. 18 depicts a cross-sectional top view of LED-based lighting module 100 . Each pocket structure is coated with a red emitting phosphor 191 or a yellow emitting phosphor 190 as shown. In this embodiment, the pocket structure with red-emitting phosphor 191 is evenly distributed with yellow-emitting phosphor 190 . In other embodiments, a greater number of pockets may be coated with one phosphor or the other to match the target color point. In some other embodiments, additional phosphors may be included in some pocket structures.

In some other embodiments, different wavelength converting materials, each comprising a combination of phosphors, may be coated with different pocket structures to match the target color point. For example, some pocket structures can be coated with a wavelength converting material that emits white light with a 3000K CCT, while other pocket structures can be coated with a phosphor that emits white light with a 4000K CCT. In this way, the combined light 140 output by the LED-based lighting module 100 can be tuned to have a CCT between 3000K and 4000K by varying the relative amounts of pocket structures that produce 3000K light and 4000K light. As shown in Figure 18, each pocket structure is uniformly square. However, in other embodiments, each pocket structure may be of any shape (eg, generally polygonal and generally elliptical). A shaped pocket structure is desired to improve output beam uniformity and color control of light emitted from LED-based lighting module 100 .

As shown in Figure 19 (and Figure 16), the pattern of pockets is characterized by a grid separation distance G, while the pattern of LEDs is characterized by an LED separation distance L. In some embodiments, the grid separation distance may be smaller than the LED separation distance (see FIG. 19 ). In some other embodiments, the grid separation distance may be the same as the LED separation distance (see FIG. 16 ). In some other embodiments, the grid separation distance may be greater than the LED separation distance (not shown). Also, as shown in FIG. 19 , the distance between the grids is greater than the width W of the pocket structure to ensure that enough light emitted from the LED 102 is color-converted by the wavelength conversion material. In some embodiments, the grid separation distance is at least twice the width W of the pocket structure.

20 illustrates a cross-sectional view of another aspect of LED-based lighting module 100 including a color conversion cavity 160 configured to disperse and color convert light emitted from LEDs 102 over a wide area. In this way, color conversion and improved output beam uniformity can be achieved in thin profile structures. As shown in FIG. 20, color conversion cavity 160a includes at least one reflective sidewall 161 that directs light emitted from LED 102a to transmissive layer 134 disposed above LED 102a. The reflective sidewall 161 is positioned at an oblique angle relative to the plane 204 on which the LED 102 is disposed. As shown in FIG. 20 , the reflective sidewall 161 extends outward and upward to the attachment point 207 of the transmissive layer 134 and the reflective sidewall 161 . Transmissive layer 134 includes a convex reflector 205 disposed over each LED 102 . As shown, the central axis of the reflector 205 is collinear with the central axis 202 of each LED 102 such that each reflector 205 is centered over each LED 102 . As shown, a portion of transmissive layer 134 is coated with wavelength converting material 206 . In this manner, light emitted from LED 102a is laterally dispersed and color converted before being emitted from color conversion cavity 160a. For example, photons 208 (eg, blue photons) are emitted from LED 102 a , reflect off reflector 205 , subsequently reflect off reflective sidewall 161 , and excite wavelength converting material 206 . The wavelength converting material 206 absorbs photons 208 and emits color converted light (eg, red light) that passes through the transmissive layer 134 and exits the color conversion cavity 160a.

As shown in FIG. 20 , color converting cavity 160a extends laterally a distance _DwG from central axis 202 of LED 102a to attachment point 207 . To facilitate the dispersion of light over a wider area, the distance H between the transmissive layer 134 and the plane 204 is less than half of _DWG . As shown, in FIG. 20, light is transmitted laterally by a series of reflections within the color conversion cavity and away from the LED 102a and then from The light emitted by the LEDs is color converted, and the color conversion cavity 160 is configured to disperse and color convert the light emitted by the LEDs 102 over a wide area. To further facilitate the lateral dispersion of light, reflectors are introduced above the LEDs to reflect the light laterally prior to color conversion.

Figure 21 illustrates a color conversion cavity 160 in another embodiment. In this embodiment, transmissive layer 134 is a translucent layer. For example, transmissive layer 134 may consist of a thin layer of sintered PTFE. As shown, the transmissive layer 134 does not include reflectors as described in the embodiment of FIG. 20 . Instead of reflectors, the translucent layer allows transmission of a portion of light emitted from each LED 102 and reflection of another portion to facilitate lateral scattering of light within each color conversion cavity.

In another embodiment, each color conversion cavity 160 includes a transparent medium 210 having a significantly higher refractive index than air (eg, silicone). In some embodiments, a transparent medium 210 fills the color conversion cavity. In some examples, the refractive index of transparent medium 210 matches the refractive index of any encapsulation material that is part of the encapsulated LED 102 . In the illustrated embodiment, a transparent medium 210 fills a portion of each color conversion cavity, but is physically isolated from the LEDs 102 . This can be expected to facilitate the extraction of light from the color conversion cavity. As shown, the wavelength conversion layer 206 is disposed on the transmissive layer 134 . In some embodiments, wavelength converting layer 206 includes multiple portions, each portion having a different wavelength converting material. Although as shown, wavelength converting layer 206 is disposed atop transmissive layer 134 such that transmissive layer 134 is positioned between wavelength converting layer 206 and each of LEDs 102, in some embodiments, wavelength converting layer 206 may be disposed on top of transmissive layer 134. layer 134 between the transmissive layer 134 and each LED 102 . Additionally, or alternatively, wavelength converting material may be embedded in transparent medium 210 .

In another aspect, LED-based lighting module 100 includes a translucent non-planar non-planar shaped window 220 disposed over and isolated from LED 102 , as shown in FIG. 22 . In some embodiments, translucent non-planar shaped window 220 may be constructed of a molded or glass material. In other embodiments, the translucent non-planar shaped window 220 may consist of a thin layer of sintered PTFE material or include a thin layer of sintered PTGE material. A shaped window physically isolated from the LEDs facilitates light mixing and color uniformity while performing color conversion. The shaping window The shaping window is surrounded by a reflector. The reflector further provides light mixing to facilitate uniformity and output beam shaping. The shaped window is designed in conjunction with the reflector to provide color control and output beam uniformity, especially for narrow output beam designs.

The translucent non-planar shaped window 220 includes a wavelength converting material that color converts a portion of the light emitted from the LED 102 . For example, as shown in FIG. 22 , blue light 223 emitted from LED 102 is absorbed by the wavelength converting material included in color converting layer 135 disposed on translucent non-planar shaped window 220 . In response, the wavelength converting material emits longer wavelength light (eg, yellow light). In the embodiment shown in FIG. 22 , said color converting layer 135 comprising a wavelength converting material is disposed on the shaped output window 220 . In some other embodiments, wavelength conversion material is embedded in the translucent non-planar shaped window 220 .

As shown in FIG. 22 , the LED-based lighting module 100 includes a reflective sidewall 161 in contact with the translucent non-planar shaped window 220 . In this manner, light emitted from LEDs 102 is directed through the translucent non-planar shaped window 220 before exiting the LED-based lighting module. In some embodiments, the reflective sidewalls 161 are coated with a wavelength converting material having different color converting properties than the wavelength converting material disposed on the translucent non-planar shaped window 220 . For example, as shown in FIG. 22 , blue light emitted from LED 102 is absorbed by the wavelength converting material disposed on reflective sidewall 161 . In response, the wavelength converting material emits longer wavelength light (eg, red light).

As shown in FIG. 22 , reflector 125 is attached to LED-based lighting module 100 to form light source 150 . The reflector 125 has an inner space 221 surrounding a translucent non-planar shaped window 220 . In this manner, light emitted from LED 102 must pass through translucent non-planar shaped window 220 before reaching the reflective surface of reflector 125 . By enclosing LED 102 with translucent non-planar shaped window 220, LED 102 is protected from environmental contamination. Additionally, the color point of the light emitted by the light source 150 is controlled as a function of the LED-based lighting module 100 independently of the reflector 125 . Furthermore, by enclosing the translucent non-planar shaped window 220, the reflector 125 is able to control the output beam profile provided by the light source 150. In some embodiments, the inner space 221 is filled with a transparent material (eg, silicone) having a refractive index greater than that of air. In this way, the extraction of light from LED-based lighting module 100 is enhanced.

In some embodiments, the translucent non-planar shaped window 220 includes a reflective portion 222 . By proper positioning of the reflective portion 222, the output beam uniformity of the light emitted by the translucent non-planar shaped window 220 can be improved. As shown in FIG. 22 , the translucent non-planar shaped window 220 includes a reflective layer disposed on the reflective portion 222 of the translucent non-planar shaped window 220 . In some other embodiments, the translucent non-planar shaped window 220 may be constructed of or include a layer of diffusely reflective material (eg, sintered PTFE). In these embodiments, a separate reflective portion 222 may not be required, as sufficient light will be reflected and redirected to another portion of the translucent non-planar shaped window 220 . In these embodiments, a portion of the translucent non-planar shaped window 220 does not include wavelength converting material.

The translucent non-planar shaped window 220 can be shaped to promote output beam uniformity and efficient light extraction from the LED 102 . In the embodiment shown in FIG. 23, the translucent non-planar shaped window 220 is dome-shaped. In some embodiments, the dome shape may be a parabolic shape configured to concentrate light emitted from LED 102 to a specified output beam angle.

In some embodiments, the LED-based lighting module 100 includes a translucent non-planar shaped window 220 disposed over the plurality of color conversion cavities 160 . As shown in FIG. 24 , by way of example, LED-based lighting module 100 includes a plurality of color conversion cavities 160 a - 160 d configured as described in FIG. 20 . The translucent non-planar shaped windows 220 are disposed above the color conversion cavities such that light emitted from each color conversion cavity passes through the translucent non-planar shaped windows 220 before interacting with the reflector 125 .

In some embodiments, components of color conversion chamber 160 may be constructed of or include PTFE material. In some examples, the assembly may include a layer of PTFE behind a reflective layer, such as a polished metal layer. The PTFE material may be formed from sintered PTFE particles. In some embodiments, any portion of the interior opposing surfaces of color conversion cavity 160 may be constructed of PTFE material. In some embodiments, the PTFE material may be coated with a wavelength converting material. In other embodiments, a wavelength converting material may be mixed with the PTFE material.

In other embodiments, the components of the color conversion cavity 160 may be constructed of or include reflective ceramic materials, such as those produced by CerFlex International (Netherlands). In some embodiments, any portion of the interior opposing surfaces of color conversion chamber 160 may be composed of a ceramic material. In some embodiments, the ceramic material may be coated with a wavelength converting material.

在一些实施例中，颜色转换腔160的内部相对表面的任何部分都可以由反射的金属材料构成。在一些实施例中，所述反射的金属材料可以涂覆波长转换材料。In other embodiments, the components of the color conversion chamber 160 may be constructed of or include a reflective metallic material, such as aluminum from Alanod (Germany) or

In some embodiments, any portion of the interior opposing surfaces of color conversion cavity 160 may be composed of a reflective metallic material. In some embodiments, the reflective metallic material may be coated with a wavelength converting material.

In other embodiments, the components of the color conversion cavity 160 may be constructed of or include reflective plastic materials, such as Vikuiti ^™ ESR sold by 3M (USA), Lumirror ^™ manufactured by Toray Corporation (Japan) E60L or microcrystalline polyethylene terephthalate (MCPET), such as manufactured by Furukawa Electric Co., Ltd. (Japan). In some embodiments, any portion of the interior facing surfaces of color conversion cavity 160 may be constructed of a reflective plastic material. In some embodiments, the reflective plastic material may be coated with a wavelength converting material.

Cavity 160 may be filled with a non-solid material, such as air or an inert gas, such that LED 102 emits light into the non-solid material. As an example, the cavity may be sealed and argon gas may be used to fill the cavity. Alternatively, nitrogen gas can be used. In other embodiments, cavity 160 may be filled with a solid encapsulating material. As an example, silicone may be used to fill the cavity.

的侧壁插入件107构成，与由未涂覆PTFE侧壁插入件107构成的相同模块的蓝光输出，所述侧壁插入件由Berghof公司(德国)制造的烧结PTFE材料构成，进行对比。通过使用PTFE侧壁插入件，来自照明模块100的蓝光输出减少7％。类似地，与未涂覆

侧壁插入件107相比，通过使用由W.L.Gore公司(美国)制造的烧结PTFE材料构成的未涂覆PTFE侧壁插入件107，来自照明模块100的蓝光输出减少5％。从所述照明模块100的光的提取与所述腔160内的反射率直接相关，因此，与其他可获得的反射材料相比，所述PTFE材料的较差的反射率将与在所述腔160中使用所述PTFE材料的目的相偏离。然而，本发明的发明人已经确定，当所述PTFE材料涂覆荧光粉时，与具有类似的荧光粉涂层的其他反射性更强的材料(诸如

)相比，所述PTFE材料意外地产生了光输出的增加。在另一个示例中，对照明模块100的白光输出，所述照明模块由荧光粉涂覆的

侧壁插入件107构成，目标相关色温(CCT)为4000K，与由荧光粉涂覆的PTFE侧壁插入件107构成的相同模块的白光输出，所述侧壁插入件由Berghof公司(德国)制造的烧结PTFE材料构成，进行比较。与荧光粉涂覆

相比，通过使用荧光粉涂覆PTFE侧壁插入件，来自照明模块100的白光输出增加7％。类似地，与荧光粉涂覆

侧壁插入件107相比，通过使用由W.L.Gore公司(美国)制造的烧结PTFE材料构成的PTFE侧壁插入件107，来自照明模块100的白光输出增加14％。在另一个示例中，对照明模块100的白光输出，所述照明模块由荧光粉涂覆的侧壁插入件107构成，目标相关色温(CCT)为3000K，与由荧光粉涂覆的PTFE侧壁插入件107构成的相同模块的白光输出，所述侧壁插入件由Berghof公司(德国)制造的烧结PTFE材料构成，进行比较。与荧光粉涂覆

相比，通过使用荧光粉涂覆PTFE侧壁插入件，来自照明模块100的白光输出增加10％。类似地，与荧光粉涂覆

侧壁插入件107相比，通过使用由W.L.Gore公司(美国)制造的烧结PTFE材料构成的PTFE侧壁插入件107，来自照明模块100的白光输出增加12％。The PTFE material ratio can be used for other materials that are constructed or included in the components of the color conversion chamber 160 (such as Alanod's ) with low reflectivity. In one example, for the blue light output of LED-based lighting module 100, the LED-based lighting module is made of uncoated

The blue light output of the same module consisting of sidewall inserts 107 made of uncoated PTFE sidewall inserts 107 made of sintered PTFE material manufactured by the company Berghof (Germany) was compared. By using the PTFE sidewall inserts, the blue light output from the lighting module 100 is reduced by 7%. Similarly, with uncoated

By using an uncoated PTFE sidewall insert 107 composed of a sintered PTFE material manufactured by WL Gore Corporation (USA), the blue light output from the lighting module 100 was reduced by 5% compared to the sidewall insert 107 . The extraction of light from the illumination module 100 is directly related to the reflectivity within the cavity 160, therefore, the poor reflectivity of the PTFE material compared to other available reflective materials The purpose of using the PTFE material in 160 is deviated. However, the inventors of the present invention have determined that when the PTFE material is phosphor-coated, it does not compare favorably with other more reflective materials with similar phosphor coatings, such as

), the PTFE material unexpectedly produces an increase in light output. In another example, for the white light output of the lighting module 100, the lighting module is made of phosphor-coated

White light output from the same module constructed from phosphor-coated PTFE sidewall inserts 107 with a target correlated color temperature (CCT) of 4000 K, manufactured by the Berghof company (Germany) Made of sintered PTFE material for comparison. Coated with Phosphor Powder

In comparison, white light output from lighting module 100 was increased by 7% by coating the PTFE sidewall inserts with phosphor. Similarly, with phosphor coated

The white light output from the lighting module 100 was increased by 14% compared to the sidewall insert 107 by using the PTFE sidewall insert 107 composed of sintered PTFE material manufactured by WL Gore Corporation (USA). In another example, for the white light output of the lighting module 100, the lighting module is made of phosphor-coated White light output of the same module constructed of sidewall inserts 107 with a target correlated color temperature (CCT) of 3000 K, made of phosphor-coated PTFE sidewall inserts 107, manufactured by the Berghof company (Germany) Made of sintered PTFE material for comparison. Coated with Phosphor Powder

Compared to that, the white light output from the lighting module 100 was increased by 10% by coating the PTFE sidewall inserts with phosphor. Similarly, with phosphor coated

The white light output from the lighting module 100 was increased by 12% compared to the sidewall insert 107 by using the PTFE sidewall insert 107 composed of sintered PTFE material manufactured by WL Gore Corporation (USA).

Accordingly, it has been found that, although less reflective, it is desirable to construct the phosphor-coated portion of the light mixing cavity 160 from PTFE material. In addition, the present inventors have also found that when exposed to the heat of the LEDs, such as in the light mixing cavity 160, compared to other more reflective materials with similar phosphor coatings, such as ) compared to phosphor-coated PTFE materials for higher durability.

Although certain specific examples are described above for instructional purposes, the teachings of this patent document have general applicability and are not limited to the specific examples described above. For example, any component of color conversion cavity 160 may be patterned with phosphors. Both the pattern itself and the phosphor composition can vary. In one embodiment, the lighting device may include different types of phosphors located in different regions of the light mixing cavity 160 . For example, red phosphor may be on either or both of the insert 107 and the bottom reflector insert 106, while yellow and green phosphors may be on the upper or lower surface of the output window 108 or Embedded within the output window 108. In one embodiment, different types of phosphors (eg, red and green) can be located on different regions on the sidewall 107 . For example, one type of phosphor can be patterned in a first area on the sidewall insert 107, such as in stripes, spots, or other pattern, while another type of phosphor is located on the side of the insert 107. different on the second area. Additional phosphors may be used and located in different regions of the cavity 160 if desired. Additionally, only one type of wavelength converting material may be used and patterned in the cavity 160 (eg, on the sidewalls) if desired. In another example, cavity 105 is used to clamp mounting plate 104 directly to mounting base 101 without using mounting plate retaining ring 103 . In other examples, mounting base 101 and heat sink 120 may be a single component. In another example, the LED-based lighting module 100 is used as part of the light source 150 as described in FIGS. 1-3 . As shown in FIG. 3, LED-based lighting module 100 may be part of a replaceable or retrofit lamp. However, in another embodiment, the LED-based lighting module 100 may be formed and considered as a replaceable or retrofit lamp. Accordingly, various modifications, adaptations and combinations of various features of the described embodiments can be practiced without departing from the scope of the present invention described in the claims.

Claims (as amended under Article 19 of the Treaty)

1. An LED-based lighting device comprising:

A side wall having a first surface area comprising a portion of an interior surface area of the first color conversion cavity, and a second surface area comprising a portion of an interior surface area of a second color conversion cavity, wherein the first surface area is coated There is a first wavelength converting material, and wherein the second surface region is coated with a second wavelength converting material;

a first LED, wherein light emitted from the first LED directly enters the first color conversion cavity and does not directly enter the second color conversion cavity; and

a second LED, wherein light emitted from the second LED directly enters the second color converting cavity and does not directly enter the first color converting cavity.

2. The LED-based lighting device of claim 1, further comprising:

A transmissive layer mounted above the first color conversion cavity and the second color conversion cavity, wherein a first portion of the transmissive layer covers the first color conversion cavity, and wherein a second portion of the transmissive layer covers The second color conversion cavity.

3. The LED-based lighting device of claim 2, wherein the transmissive layer is coated with a third wavelength converting material.

4. The LED-based lighting device of claim 2, wherein the transmissive layer is coupled to the sidewall.

5. The LED-based lighting device of claim 1, wherein the first wavelength converting material and the second wavelength converting material are the same material.

6. The LED-based lighting device of claim 3, wherein any one of the first wavelength converting material, the second wavelength converting material, and the third wavelength converting material is selected such that from the LED-based The color point of the output light emitted by the lighting device matches the target color point.

7. The LED-based lighting device of claim 1, wherein the current supplied to the first LED is selected such that a color point of output light emitted from the LED-based lighting device matches a target color point.

8. The LED-based lighting device of claim 1, further comprising:

A second light mixing cavity disposed above the first color conversion cavity and the second color conversion cavity, the second light mixing cavity includes:

reflective side walls, and

The output window of the LED-based lighting device.

9. The LED-based lighting device of claim 1, wherein the peak emission wavelength of the first LED is different than the peak emission wavelength of the second LED.

10. An LED-based lighting device comprising:

Multiple LEDs;

a translucent non-planar shaped window disposed over and spaced from the plurality of LEDs, the translucent non-planar shaped window including a reflective portion disposed at an apex of the translucent non-planar shaped window and a first wavelength converting material that color converts a portion of light emitted from the plurality of LEDs, wherein a reflector attached to the LED-based lighting device has a reflector that surrounds the translucent the interior space of a window of non-planar shape; and

A first color conversion cavity comprising reflective sidewalls disposed between the plurality of LEDs and the translucent non-planar shaped window along a plane direction from which at least one LED of the plurality of LEDs is disposed extending in the direction of the transmissive layer in between, wherein a portion of the transmissive layer is coated with the second wavelength converting material.

11. The LED-based lighting device of claim 10, wherein the reflective sidewall comprises a third wavelength converting material.

12. The LED-based lighting device of claim 10, further comprising:

a mounting board on which the plurality of LEDs are attached; and

A base reflector disposed above the mounting plate.

13. The LED-based lighting device of claim 10, wherein the translucent non-planar shaped window is dome-shaped.

14. The LED-based lighting device of claim 10, wherein the plurality of LEDs are mounted in the plane and wherein a surface of the translucent non-planar shaped window is oriented at an oblique angle relative to the plane.

15. The LED-based lighting device of claim 10, wherein the reflective sidewall surrounds the at least one LED of the plurality of LEDs and is oriented at an oblique angle relative to a plane on which the at least one LED is disposed. .

16. The LED-based lighting device of claim 10, further comprising:

A second color conversion cavity disposed between a second LED of the plurality of LEDs and the translucent non-planar shaped window, wherein a portion of an interior surface area of the second color conversion cavity is coated with a third wavelength conversion A material wherein light emitted from a first LED of the plurality of LEDs directly enters the first color converting cavity and does not directly enter the second color converting cavity, and wherein light emitted from the second of the plurality of LEDs Light emitted by the LED directly enters the second color conversion cavity and does not directly enter the first color conversion cavity.

17. A device comprising:

an LED of a plurality of light emitting diodes LEDs disposed in a first plane, the LED having a central axis extending perpendicular to a die area of the LED;

a color conversion cavity comprising: a reflective sidewall surrounding the LED, wherein the reflective sidewall is oriented at an oblique angle relative to the first plane and extends from the first plane to a second plane, the second plane a first distance above the first plane; and a transmissive layer disposed in the second plane and attached to the reflective sidewall, wherein a portion of the transmissive layer is coated with a first wavelength converting material, and wherein the first distance is less than half the distance measured in the second plane from the point of attachment of the transmissive layer to the reflective sidewall to the central axis of the LED; and

A convex spherical reflector attached to the transmissive layer and disposed above the LED between the transmissive layer and the LED.

18. The apparatus of claim 17, further comprising:

A window is disposed over and spaced from the transmissive layer, wherein a portion of the window is coated with a second wavelength converting material.

19. The device of claim 17, wherein the reflective sidewall is diffusely reflective and at least a portion of the reflective sidewall is coated with the first wavelength converting material.

20. The device of claim 17, wherein a space between the LED and the reflective sidewall is filled with a solid transparent medium.

21. The device of claim 20, wherein the first wavelength converting material is embedded in the solid transparent medium.

Claims (23)

1. a LED-based lighting apparatus, comprising:

Sidewall, the first surface region with a part for the inner surface area that comprises the first color conversion chamber, and the second surface region of a part that comprises the inner surface area in the second color conversion chamber, wherein said first surface region is coated with the first material for transformation of wave length, and wherein said second surface region is coated with second wave length transition material;

The one LED, wherein directly enters described the first color conversion chamber and does not directly enter described the second color conversion chamber from the light of a described LED transmitting; And

The 2nd LED, wherein directly enters described the second color conversion chamber and does not directly enter described the first color conversion chamber from the light of described the 2nd LED transmitting.

2. LED-based lighting apparatus according to claim 1, also comprises:

The transmission layer that is arranged on described the first color conversion chamber and described the second top, color conversion chamber, the first of wherein said transmission layer covers described the first color conversion chamber, and the second portion of wherein said transmission layer covers described the second color conversion chamber.

3. LED-based lighting apparatus according to claim 2, wherein said transmission layer is coated with three-wavelength transition material.

4. LED-based lighting apparatus according to claim 2, wherein said transmission layer is coupled to described sidewall.

5. LED-based lighting apparatus according to claim 1, wherein said the first material for transformation of wave length and second wave length transition material are identical materials.

6. LED-based lighting apparatus according to claim 3, is wherein chosen as any of described the first material for transformation of wave length, described second wave length transition material and described three-wavelength transition material the color dot making from the output light of LED-based lighting apparatus transmitting and mates with color of object point.

7. LED-based lighting apparatus according to claim 1, wherein selects to be supplied to the electric current of a described LED, makes to mate with color of object point from the color dot of the output light of described LED-based lighting apparatus transmitting.

8. LED-based lighting apparatus according to claim 1, also comprises:

The the second smooth hybrid chamber that is arranged on described the first color conversion chamber and described the second top, color conversion chamber, described the second smooth hybrid chamber comprises:

Reflective side walls, and

The output window of described LED-based lighting apparatus.

9. LED-based lighting apparatus according to claim 1, the peak emission wavelength of a wherein said LED is different from the peak emission wavelength of described the 2nd LED.

10. a LED-based lighting apparatus, comprising:

A plurality of LED;

Be arranged on described a plurality of LED top and with the isolated translucent molded non-planar window of described a plurality of LED, described translucent molded non-planar window comprises the first material for transformation of wave length, described the first material for transformation of wave length carries out color conversion to a part for the light from described a plurality of LED transmittings, and the reflector that is wherein pasted to described LED-based lighting apparatus has the inner space that surrounds described translucent molded non-planar window; And

The the first color conversion chamber that comprises reflective side walls, described reflective side walls is along extending to the direction that is arranged on the transmission layer between described a plurality of LED and described translucent molded non-planar window from being provided with the plane of at least one LED of described a plurality of LED, and a part for wherein said transmission layer is coated with second wave length transition material.

11. LED-based lighting apparatus according to claim 10, wherein said reflective side walls comprises three-wavelength transition material.

12. LED-based lighting apparatus according to claim 10, also comprise:

On it, be pasted with the installing plate of described a plurality of LED; And

Be arranged on the pedestal reflector of described installing plate top.

13. LED-based lighting apparatus according to claim 10, wherein said translucent molded non-planar window is domeshape.

14. LED-based lighting apparatus according to claim 10, wherein said translucent molded non-planar window comprises the reflecting part on the summit that is arranged on described translucent molded non-planar window.

15. LED-based lighting apparatus according to claim 10, wherein said a plurality of LED be arranged in described plane and the surface of wherein said translucent molded non-planar window with respect to described plane become angle of inclination towards.

16. LED-based lighting apparatus according to claim 10, wherein said reflective side walls around described at least one LED in described a plurality of LED and with respect to the plane that is provided with described at least one LED become angle of inclination towards.

17. LED-based lighting apparatus according to claim 10, also comprise:

The second color conversion chamber, be arranged between the 2nd LED and described translucent molded non-planar window of described a plurality of LED, a part for the inner surface area in wherein said the second color conversion chamber is coated with three-wavelength transition material, wherein the light of the LED transmitting from described a plurality of LED directly enters described the first color conversion chamber and does not directly enter described the second color conversion chamber, and the light of wherein the 2nd LED transmitting from described a plurality of LED directly enters described the second color conversion chamber and directly do not enter described the first color conversion chamber.

18. 1 kinds of devices, comprising:

Be arranged on LED in a plurality of LEDs in the first plane, described LED has along the central shaft vertically extending with the die area of described LED; And

Color conversion chamber, comprise: around the reflective side walls of described LED, wherein said reflective side walls with respect to described the first plane become angle of inclination towards and from described the first plane, extend to the second plane, described the second plane is positioned at described first plane top the first distance; And be arranged in described the second plane and be pasted to the transmission layer of described reflective side walls, a part for wherein said transmission layer is coated with the first material for transformation of wave length, and wherein said the first distance is less than the attachment point from described transmission layer and described reflective side walls measured in described the second plane to half of the distance of the central shaft of described LED.

19. devices according to claim 18, also comprise:

Protruding spheric reflection body, be pasted to described transmission layer and between described transmission layer and described LED, be arranged at described LED above.

20. devices according to claim 18, also comprise:

Window, is arranged on the top of described transmission layer and spaced apart with described transmission layer, and a part for wherein said window is coated with second wave length transition material.

21. devices according to claim 18, wherein said reflective side walls is irreflexive and at least a portion of described reflective side walls is coated with described the first material for transformation of wave length.

22. devices according to claim 18, wherein the space between described LED and described reflective side walls is by solid transparent Filled Dielectrics.

23. devices according to claim 22, wherein said the first material for transformation of wave length is embedded in described solid transparent medium.

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